Steam Turbine Business Unit

3800 West Avenue

Burlington, IA 52601
Ph: 319-753-5431
FAX: 319-752-1616

Murray Steam Turbine

Installation, Operation and Maintenance

Important Information on Steam Turbines

(Condensing)

07/20/11
COPYRIGHT
© Murray Turbomachinery, 1993
All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language, in any form, by any means, without permission in
writing from Murray Turbomachinery.

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 TABLE OF CONTENTS

Section Page Section Page

1 General Specifications 5.10 Handvalves 25
1.1 Unpacking 5 5.11 Sentinel Warning Valve 26
1.2 Storage 5 5.12 Steam Strainers 26
1.3 Cleaning 5 5.13 Gland Evacuation Equipment 26
5.14 Condensing Multi-Stage Turbines 27
2 Special Conditions
2.1 Top Exhaust 6 6 Operating The Turbine
2.2 Outdoor Installation 6 6.1 Operation 28
2.3 Quick Starting & Standby 6 6.2 Turbine Operating Instructions 28
Service
2.4 Reversed Rotation 6 6.3 Precautions 30

3 Installation & Mounting 7 Maintenance & Inspection

3.1 Installation 7 7.1 Maintenance & Inspection 31
3.2 Foundation & Baseplate 7 7.2 Internal Inspection 32
3.3 Erection 8
3.4 Alignment 8 8 Spare Parts & Field Service
3.5 Piping 14 8.1 Spare Parts 34
3.6 Recommended Blow-Down 15 8.2 Field Service 34
Procedure

4 Steam Seals 9 Steam Purity/Turbine Deposits

4.1 Gland Leak-Off System 16 9.1 Introduction 35
4.2 Gland Seal System – 17 9.2 Steam Purity 35
Condensing Turbines
4.3 Leak-Off Piping & Drains 18 9.3 Effects of Deposits on Turbine 35
9.4 Detection of Deposits 36
5 Ancillary Equipment 9.5 Detection of Corrosion 36
5.1 Governors 19
5.2 Governor Valve 20 10 Off-Season Storage
5.3 Trip Systems 20 10.1 Introduction 37
5.4 Ring Oil Lubrication 20 10.2 Turbine Steam Path 37
5.5 Pressure Lubrication 22 10.3 Lubrication System 38
5.6 Oil Flush Procedure 24 10.4 Other Recommendations 38
5.7 Lube Oil Recommendations 24
5.8 Bearings 25
5.9 Couplings 25

INTRODUCTION

There are several considerations and precautions in connection with installation, operation and
maintenance that must be understood and which apply to steam turbines in general, regardless of
size and type. That is the nature of the material in this manual.

This information must be familiar to all involved with the installation, operation and maintenance of
steam turbines. Even those previously experienced with steam turbines will find this material helpful.

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 1
GENERAL INFORMATION

1.1 Unpacking

Murray steam turbines are carefully tested and adjusted at the factory before shipping. Then they are
packed and protected for shipment. Despite precautions taken at the factory, accidental damage may
result from improper handling during shipment. For that reason, it is extremely important that the
machine is unpacked carefully and that any damage is noted for a claim against the carrier.

Always check the shipment against the shipping manifest. DO NOT DISPOSE OF THE SHIPPING
CONTAINER UNTIL AFTER ACCOUNTING FOR ALL PARTS. Small, loose parts and accessories
are frequently removed from the turbine before shipment, boxed separately, and fastened to the
inside of the larger shipping box or crate.

1.2 Storage

Protective treatment is factory applied to turbine parts subject to corrosion. Transit carriers and
recipients of turbines are advised to take precautions against exposure of turbines to the elements.

Should it become necessary to store a turbine for a long period of time, Dresser-Rand should be
contacted for special storage procedures.

WHEN STORING A TURBINE PRIOR TO INSTALLATION, PRECAUTIONS MUST BE TAKEN TO

AVOID DAMAGE DUE TO CORROSION AND DIRT. THE MACHINE SHOULD BE STORED IN A
CLEAN, DRY, SHELTERED PLACE IF AT ALL POSSIBLE. IF NO SHELTER IS AVAILABLE, IT
SHOULD BE COVERED WITH WATERPROOF MATERIAL. Do not leave a turbine exposed to a
corrosive atmosphere. Even if the turbine is to be installed in the open air, precautions must be taken
to assure satisfactory condition when the turbine is started. The effects of storage differ widely with
local conditions.

1.3 Cleaning

Before a turbine is operated, certain parts must be cleaned to remove the effects of transit and
storage. Protective mylar sheets installed between the journal bearing and the shaft journal MUST
BE REMOVED PRIOR TO ROTATING THE SHAFT. (See Section 5.5 for instructions) Bearing caps
are easily removed. The interior of the bearing cases must be inspected for dust or other grit. If any
is present, the interior of the bearing cases must be flushed with kerosene or similar solvent.

Mechanical governor parts should be thoroughly washed with a spray of non-acetate solvent to
remove adhering dust particles. The interior of the turbine casing should be thoroughly cleaned so
the exhaust system will not become contaminated with dirt. This can be done easily with a water
hose through the exhaust opening. Valve stems and other exposed machined surfaces should be
cleaned with solvent to remove protective grease and/or dirt.

Exposed machined parts have been masked prior to painting. This masking serves as added
protection during shipment and is not removed before shipping. MASKING SHOULD BE REMOVED
DURING THE CLEANING PROCEDURE.

All loose parts (such as loose piping, etc.) should be cleaned and installed. Turbines packed for
export, or protected for long storage periods may need to be completely dismantled and cleaned to
remove all protective grease and flushing compound. Dresser-Rand will provide specific instructions
for turbines requiring complete dismantling.
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SPECIAL CONDITIONS

2.1 Top Exhaust

When required by site conditions, turbines are equipped with exhausts which point upward.
Turbines with a top exhaust must be provided with some means for keeping the turbine casing
drained. Dresser-Rand will provide specific instructions for each turbine shipped with a top exhaust.

2.2 Outdoor Installation

When specified on a purchase order, Murray turbines will be made suitable for outdoor installations.
However, if these machines are allowed to stand idle, corrosion will be more rapid and there is a
greater chance of the oil being contaminated with dirt and/or water. CONTACT DRESSER-RAND
FOR SPECIFIC INSTRUCTIONS BEFORE ALLOWING A TURBINE INSTALLED OUTDOORS TO
STAND IDLE.

2.3 Quick Starting & Stand-by Service

Turbines may be specified and used as a stand-by for motor drive installations. In such cases they
may be started automatically upon failure of the regular equipment. Starting is usually accomplished
by means of a control operating a motor operated throttle valve.

Some turbines used in quick starting applications must be maintained in a “warm” condition by having
a quantity of steam (to be specified by Dresser-Rand) passing through them at all times to ensure
safe start-up.

Turbines used only for stand-by should be operated for a short period at least once a month to ensure
that they will function properly when needed.

2.4 Reversed Rotation

Before running the turbine with the driven machine, be sure that no condition exists which can
produce reverse operation. As the turbine’s operating force diminishes in the stopping process, a
counterflow of process fluid (in case of centrifugal machines) may produce reversed rotation.

In such instances the speed governor and emergency overspeed governor are completely ineffective
since they control the supply of steam to the turbine.

Check-valves in the fluid lines (or non-reverse pawls in the driven machine) are common means used
to prevent reverse rotation. These items must be adequately maintained to ensure proper operation.

REVERSE ROTATION INVARIABLY RESULTS IN LUBRICATION FAILURE AND CONSEQUENT

DAMAGE TO LUBRICATED SURFACES UNLESS AN AUXILIARY OIL PUMP IS PROVIDED. IN
EXTREME CASES, THE TURBINE MAY OVERSPEED IN REVERSE TO THE POINT OF
DESTRUCTION.

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INSTALLATION & MOUNTING

3.1 Installation

Proper installation is extremely important. To obtain maximum service from Murray turbines it is
essential that turbines, reduction gears (when used), and on-site driven machines are installed with
the greatest care.

NOTE THAT DISTORTION OF THE BASEPLATE OR GENERAL MISALIGNMENT CAN CAUSE

SERIOUS FUTURE OPERATING DIFFICULTIES EVEN THOUGH THE TURBINE SEEMS TO RUN
SATISFACTORILY WHEN FIRST INSTALLED.

3.2 Foundation & Baseplate

Turbines, driven machines and reduction gears (when used) are customarily mounted on fabricated
steel baseplates. When baseplates are furnished, holes for the hold-down bolts are pre-drilled in the
baseplate. These baseplates are fastened to the foundation with anchor bolts and grouted. In some
cases, steel soleplates are used instead of baseplates under the entire unit.

Equipment should be located and aligned on the baseplate at site, in accordance with the outline
drawings, because it is not practical to locate and dowel rotating equipment to the baseplate at the
factory. Although the equipment has been assembled and operated as a unit in the factory, IT MUST
NOT BE ASSUMED THAT THE EQUIPMENT IS IN PROPER ALIGNMENT AFTER SHIPMENT
AND HANDLING.

Certified outline drawings will contain sufficient information (weights, dimensions, mounting hole
locations, etc.) to allow the user’s civil engineer to design the turbine foundation.

It is important that the top surface of concrete foundation is left rough to provide a good bond
between the grout and the foundation.

A convenient means of leveling the baseplate is to have foundation bolts threaded down to a point
flush with the top of the foundation and provide nuts for the foundation bolts for use under the
baseplate.

When the baseplate is lowered onto these nuts, they can be used in raising and leveling the base. If
it is not possible to provide for leveling in this manner, flat shims should be placed on opposite side of
each foundation bolt.

A vertical space of one inch should be provided for grouting. Less space is difficult to fill, while more
will increase shrinkage. Foundation bolts should be tightened only sufficiently to hold the baseplate
or soleplate in position while grouting, thus eliminating danger of springing.

When the baseplate is bolted and leveled, a retaining form can be built to retain the grout. The grout
should only be thin enough to flow readily. Excessive water produces greater shrinkage in drying.

Use a grout with non-shrink additives and be certain that the grout thoroughly fills the space. In
grouting soleplates, a two inch wide grout should surround the soleplate and be poured even with the
top of the soleplate.

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3.3 Erection

Where all units of turbine driven equipment are to be installed on a common base, the following
erection guideline must be used.

• Place the baseplate with its equipment on the foundation over the foundation bolts. The position
of the turbine and other equipment should approximate the unit’s intended location on the
baseplate. Loosely bolt the equipment to the baseplate.

• Locate the baseplate in a horizontal plane on the foundation to suit existing conditions.

• Raise the entire baseplate from the foundation to the height to be allowed for grout. In most
cases, this is accomplished with bars and wedges. If nuts have been provided on the foundation
bolts under the baseplate, they can be used for this purpose.

• LEVEL THE BASEPLATE CAREFULLY USING AN ACCURATE METHOD ON A MACHINED

PAD OF THE BASE. THIS CAN BE ACCOMPLISHED WITH A TRANSIT, LASER OR SPIRIT
LEVEL (MINIMUM SIX FOOT LENGTH).

• Level and align the turbine and driven machine, locating equipment properly on the baseplate in
accordance with the outline drawing and maintaining the proper distance between the ends of
each shaft. See Section 3.4 for alignment procedures.

• Moderately tighten the foundation bolts and recheck the level of the baseplate and the alignment
and level of the turbine and driven machine.

• Tighten hold-down bolts and recheck level and alignment.

UNTIL THE UNIT HAS BEEN PROPERLY DOWELED, IT CANNOT BE SAFELY ASSUMED
THAT THE EQUIPMENT WILL REMAIN PROPERLY ALIGNED ONCE THE FOUNDATION
BOLTS AND MACHINE HOLD-DOWN BOLTS HAVE BEEN TIGHTENED.

THE IMPORTANCE OF HAVING THE TURBINE AND DRIVEN MACHINE IN CORRECT

ALIGNMENT AFTER ALL INSTALLATION WORK HAS BEEN COMPLETED CANNOT BE
OVER-EMPHASIZED.

• Grout the base to the foundation. For suggestions on grouting, refer to instructions on foundation
and baseplate in section 3.2.

• After grouting has cured, retighten all bolts and again check the alignment. The equipment is
then ready to be fitted with piping.

3.4 Alignment

“Alignment” refers to the proper relationship between the centerlines and the distance between the
turbine shaft and the driven machine.

INACCURATE ALIGNMENT CAN RESULT IN DESTRUCTIVE VIBRATION, LOOSENING OF

GROUT, BURNED OUT BEARINGS, A BENT SHAFT, AND OTHER CONDITIONS THAT COULD
LEAD TO EQUIPMENT FAILURE.

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The following instructions and suggestions are made for guidance in alignment of newly installed
equipment and under the presumption that:

• The persons reading this have a general familiarity with high speed turbomachinery and that they
are aware of the basic principles of alignment.

• It is understood that the various procedures suggested for checking completed portions of the
system are in no way a substitution for proper design, engineering, and construction.
Additionally, the suggestions made represent only one of several acceptable alternatives.

• In the case of turbomachinery, many of the items vital to a good alignment have been done well
ahead of the actual “cold alignment” of the equipment. Unless the person responsible for the
alignment has first-hand knowledge that the preparations have been done properly, it is best to
verify these items. Some areas that warrant specific attention would be:

Piping. Assure that the piping is installed in agreement with design criteria, that it is
complete, and that it is in its functional state. Look for proper placement and adjustment of
guides, anchors, and supports; proper adjustment of tie-bolts on expansion joints; correct
positioning of spring hangers; complete make-up of flanges with gaskets in place and bolts
tightened; absence of slip-blinds which may have been installed for hydrotesting of pipelines; and
proper orientation of check valves.

Check the grouting to assure it is complete and appears to be well done.

Check all foundation bolts to assure tightness.

Check all shim packs for rust, improperly cut shims, folds and wrinkles, burrs, hammer marks,
and dirt. Shims are a vital link between the machine and the foundation and are essential to the
maintenance of alignment over long periods. Good practice dictates that as few shims as
possible be used, replace many thin shims with fewer shims of greater thickness. Shims of
stainless steel will pay for themselves many times over by minimizing shim deterioration. Also it
is important to make sure the equipment supports and soleplate/baseplate are clean and in good
condition.

Check for misalignment of machine supports relative to the soleplate, this is sometimes
referred to as a “soft foot” condition. Mounting a dial indicator on the machine support with the
indicator stem resting on the soleplate can make a simple test for this condition. Watch the
indicator as the hold-down bolts are loosened. If the movement of the indicator is more than
.005”, it is an indication of a problem which must be rectified. It is also appropriate to remove the
shim pack and check with feeler gauges to assure that the machine support is parallel with the
soleplate.

Check for piping strain. This can be accomplished by placing dial indicators on the machine
to monitor both vertical and horizontal movement of the casing or shaft. Then loosen all of the
hold-down bolts. If the machine moves more that the average observed in checking individual
supports, it is obviously the result of an external force and probably the piping.

Make sure that the bearings have been properly installed in the machines, are lubricated, and
the bearing covers are properly tightened.

The term “cold alignment” refers to the position of the centerline of the shaft of one piece of
equipment relative to the centerline of the shaft of an adjoining machine to which it is connected, as
well as the distance between the two shafts, with the machines in a non-operating or “cold” condition.
The term implies both offset and angularity. The importance of this cold alignment is that it is usually
the only check made to ascertain directly the relative position of the two shafts. The result of this
check is the basis for determining shaft alignment of the equipment during operation. It is the
fundamental benchmark and must be accurately done and properly recorded.

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Many methods can be utilized to perform this alignment. The method described in this manual will be
that of using dial indicators. While the method of employing dial indicators is an old and well-
established technique, it is not without problems.

The most widely used of the traditional alignment methods is commonly referred to as the “Face-
O.D.” method as illustrated in Figure1. As shown in the figure, a bracket is attached to one shaft and
extends to the proximity of the coupling hub on the adjacent shaft. Dial indicators are affixed to this
bracket with the stem of one indicator resting on the face of the coupling hub and the stem of the
other indicator resting on the outside diameter of the same hub. The offset of the shafts is
determined by the “O.D.” readings, while angularity of the shafts is determined by the “face” readings.
It is suggested that the proper distance between the shafts be established before any alignment
method is used. This spacing dimension can be found on the outline drawing and/or the coupling
drawing for the specific project.

To eliminate inaccuracies in geometry of the coupling hub, turning of both shafts simultaneously such
that the indicator readings are taken always at the same place on the hub will give more precision.
This precaution can be difficult on larger equipment and may not be possible.

Face measurements taken by this method must have the axial float of the two shafts accounted for.
Axial movement must be taken into account when turning the shafts on equipment with hydrodynamic
thrust bearings or no thrust bearings. (Small machinery utilizing ball bearings will not encounter any
axial float.) The shafts must have axial positions rechecked each time a reading is taken. One
additional element that must be accounted for is the difference between the exhaust end shaft rise
and the steam end shaft rise. Typically, the steam end will rise more than the exhaust end due to
higher temperatures. This will result in the desire to have the coupling face “open” at the top. The
calculated shaft rise for both the steam and exhaust end can be found on the outline drawing for the
project.

Care must also be taken in the brackets that are used to hold the dial indicators. “Universal” or
makeshift brackets contrived on the spur of the moment can give inaccurate readings, which can lead
to improper alignments. Especially when the spans between the shafts are quite long, care must be
taken to assure that the bracket being utilized is stiff enough that it will not deflect under its own
weight.

A step up in accuracy and the elimination of some of the problems mentioned above with the “Face
O.D.” would be to utilize the “Reverse Indicator” method as illustrated in Figure 2. This method

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employs indicator readings taken on the outside diameter of the coupling hubs or shaft only. The
sketch indicates two brackets used simultaneously, which is normally the preferred method. One
bracket could be utilized by switching back and forth for each set of readings but this is far less
convenient.

Use of the “Reverse Indicator” method eliminates the requirement for removing the coupling spacer in
a majority of cases. This reduces the wear and tear on the coupling. The error caused by coupling
hub run-out is entirely eliminated since both shafts turn as a unit (with spacer installed), and angular
misalignment is greatly magnified and more precisely diagnosed. Since face readings are eliminated,
there is no concern about axial float.

The single problem that carries over to the “Reverse Indicator” method which was present in the
“Face O.D.” method is that of deflection in the alignment bracket. This problem can be readily
handled by building the bracket with substantial material to prevent droop or by determining the
deflection in the alignment fixture and making the appropriate corrections in the alignment data.

For the purpose of example, Figure 3 shows a simple turbine-compressor to be aligned. It is desired
to place the compressor shaft .008” higher than the turbine to accommodate for calculated thermal
growth of the two machines. The alignment bracket is clamped to the turbine shaft with the indicator
stem resting upon the compressor shaft (or the rigid portion of the coupling hub).

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 The indicator is “zeroed” on top and the following readings are observed as the shafts are
rotated at 90-degree intervals.

-6 -8 Turbine to Compressor

-14

A similar procedure is used with the complementary bracket and the indicator yields to
following:

+8 +12 Compressor to Turbine

+20

This data obtained is adequate to determine relative shaft positions. Record the readings
and indicate precisely what they represent. As they are shown above, the readings shown as
“Turbine to Compressor” indicates the alignment bracket is on the turbine shaft and the
indicator stem rests upon the compressor shaft.

Make any corrections for the deflection of the alignment bracket. For this example, we will
assume .004” TIR deflection. To make the correction for this error, simply add the TIR
reading (in mils) to the bottom number in each set.

0 0

-6 -8 +8 +12

-10 +24

Turbine to Compressor Compressor to Turbine

For ease of plotting, change each pair of numbers to “zero” and a positive number. Since
diametrically opposed numbers represent only a deviation from an arbitrary reference, a
given amount may be added to both sides without affecting the meaning. On the “Turbine to
Compressor” readings, for example, 10 is added to the vertical pair of numbers while 8 is
added to the horizontal pair. The other sets are handled in a similar manner. The absence of
negative numbers reduces errors in plotting.

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 +10 0

+2 0 0 +4

0 +24

Turbine to Compressor Compressor to Turbine

In Figure 4, the points shown above have been plotted on a scaled sketch of the turbomachinery
train. Any convenient scale may be used. In this example, it is assumed the turbine will remain
stationary and the compressor will be shimmed to achieve the desired alignment. From the “Turbine
to Compressor” data, it can be seen that the centerline of the compressor shaft is .005” (one half of
the TIR reading) above the centerline of the turbine shaft for the point at which the indicator readings
were taken. Now referring to the “Compressor to Turbine” data, it can be seen the centerline of the
turbine shaft is .012” below the centerline of the compressor shaft for the point at which the indicator
readings were taken. With these two points determined, the position of the compressor shaft relative
to the turbine shaft is fixed. An extension of a line through these two points gives a graphical
representation of the alignment situation and indicates the shimming necessary to achieve the
desired alignment. It is also at this point in the alignment procedure that the offset required due to the
steam end rise be greater than the exhaust end rise must also be taken into consideration.

In this example, the vertical plane has been plotted. Alignment in the horizontal plane is obtained in
the same manner.

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In recent years people have questioned the value of the traditional “Hot Check Alignment”. Not only
is it costly and time-consuming to bring a machine up to temperature, stop it, break couplings, and
attempt to determine alignment before it cools off, but the results are highly questionable. It is
normally not possible to make the check quickly enough to accurately determine the thermal growth
of the equipment. Also any hydraulic forces and torque reactions, which can be significant, are never
revealed by the traditional check methods because the forces disappear immediately upon stopping
the machine. Today’s generally accepted, superior alternative is to use the cold position of the shafts
as a benchmark, and deduce the hot alignment by monitoring the movement of the machine casings,
or shafts, from the cold position to the hot position. There are several methods used for this
monitoring. A variety of techniques have been applied to the actual determination of casing or shaft
movement. The most widely publicized methods employ optical or electronic (laser) techniques.

3.5 Piping

Inlet and exhaust piping for a steam turbine should be designed and installed by knowledgeable
persons experienced in turbine work.

The size of steam and exhaust lines indicated on the drawing is based upon velocities in the piping
generally accepted as being good practice for runs of straight pipe up to 200 feet, or the equivalent in
valves and fittings.

Piping for back pressure turbines should include a throttle valve in the steam inlet line and a stop
valve in the exhaust line. A suitable relief valve to protect the turbine exhaust casing must be
provided between the turbine exhaust flange and the exhaust stop valve.

Piping for condensing turbines should include a throttle valve in the steam inlet line. A suitable relief
valve or rupture disc to protect the turbine exhaust casing and surface condenser must be provided at
an appropriate location in the exhaust system before any shut-off valves, if present. Often the
location of choice is on the surface condenser.

The exhaust relief valve or the rupture disc should correspond in size to those indicated for steam
and exhaust lines in APPENDIX-A, NEMA SM23-8, Steam Piping Systems. These relief valves serve
to protect the turbine casing against over-pressurization in case the turbine is started with the exhaust
valve closed or the backpressure rises for any reason during operation.

The relief valve should be of sufficient capacity to relieve the rated steam flow of the turbine at the
maximum operating pressure specified when all hand valves are opened. Contact Dresser-Rand for
specifications on sizing the valve, relieving capacity, and over-pressurization limits.

No responsibility is assumed by Dresser-Rand in regard to pressure or temperature drops. THE

PERFORMANCE OF THE TURBINE SPECIFIED IS BASED UPON THE INLET PRESSURE AND
TEMPERATURE AS MEASURED AT THE MURRAY TURBINE STEAM INLET FLANGE.
SIMILARLY, THE EXHAUST PRESSURE IS MEASURED AT THE TURBINE EXHAUST FLANGE.

Steam and exhaust piping must be properly designed and supported so that its weight and thermal
expansion will not produce excessive strains on the turbine inlet or exhaust flanges, either when cold
or when at normal operating temperature. The piping must be designed so that it does not have to be
sprung into position for bolting to the turbine flanges when cold. Likewise, the piping must not spring
out of position when everything is at running temperature.

FORCE DUE TO THERMAL EXPANSION CAN BE VERY GREAT IF NOT PROVIDED FOR BY
EXPANSION AND SUPPORT OF PIPING.

These forces can cause misalignment. The maximum allowable forces and moments, per NEMA
standards, are indicated on the outline drawings. See Appendix A, NEMA SM23, Part 8 (Steam
Piping Systems) for additional information.

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Moisture in the inlet steam not only increases the steam consumption but causes rapid wear of the
valve seats, nozzles and turbine blades. Contact Dresser-Rand for the maximum amount of moisture
allowable on each specific application.

Where turbines are to operate on saturated steam, a steam trap should be installed at the low point of
the inlet piping. In most cases, a moisture separator in addition to the steam trap is advisable.

Where exhaust piping bends upward after leaving the turbine, steam traps should be provided to
keep the exhaust line drained to prevent water from building up in the exhaust pipe and turbine
casing.
FAILURE TO KEEP THE EXHAUST LINE DRAINED MAY RESULT IN A RESTRICTION IN THE
EXHAUST LINE, CAUSING A LOSS OF POWER AND DAMAGE TO THE TURBINE ROTOR.

Connecting the steam line should always begin at the header or other source, the turbine connection
being made last. If an expansion joint is used in either line it must be securely anchored to prevent
axial strain on the turbine.

BE SURE TO BLOW OUT AND CLEAN ALL STEAM LINES BEFORE CONNECTING TO THE
TURBINE. FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE STEAM STRAINER
SCREEN AND OTHER INTERNAL PARTS.

DRESSER-RAND ACCEPTS NO RESPONSIBILITY FOR DAMAGE RESULTING FROM THE

ENTRANCE OF FOREIGN MATERIALS.

3.6 Recommended blow-down procedure

Newly constructed steam piping should be blown-down to remove scale, weld beads and any other
foreign material. Such material can cause severe damage if it enters the steam turbine.

The blow-down connection should be as close to the turbine as possible. The diameter of the blow-
down connection should be a minimum of one half the diameter of the line being blown-down to
ensure that steam velocity in the piping is high enough to break loose and carry away any foreign
material stuck to the inside of the piping.

Blow-down should be done before the piping is insulated. Steam at full temperature and pressure
should be bled through the piping.

After the piping has been warmed up, the valve in the blow-down connection should be opened wide
for about 15 seconds to allow live steam to blow out any loose material in the piping. Piping should
be allowed to cool down to room temperature, about 6-8 hours.

Thermal expansion and contraction which occurs during warming up and cooling down, helps break
loose the foreign material inside the piping. Hammering around any welded joints in the piping will
also help to break loose foreign material

The above procedures of warm-up, blow-down and cool-off should be repeated as many times as
necessary to clean all foreign materials out of the piping. To check for clean piping, a target should
be placed about two feet away from the blow-down opening so that the steam will hit the target, and
any solids in the steam will become embedded in the target. Aluminum and polished stainless steel
are commonly used target materials. Piping can be considered clean when no embedded particles
and indentations are found in the target after a 15 second blow-down.

REMOVAL OF FOREIGN MATERIAL FROM THE PIPING IS THE RESPONSIBILITY OF THE

PARTY INSTALLING THE PIPING. The turbine warranty does not cover damage due to the
entrance of foreign material.

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 4

STEAM SEALS

4.1 Gland leak-off system

Steam in non-condensing turbines tends to leak around the shaft since the pressure in the casing is
greater than atmospheric. Leaks should be limited for the following reasons:

• Steam finds its way to the bearing housings, condenses there and contaminates the oil.

• Efficiency is reduced since escaped steam produces no useful work.

• Each pound of steam lost requires adding one pound of make-up water to the boiler

• Excessive leaks cause an unpleasant working atmosphere.

The gland leak-off system for non-condensing applications and the gland seal system for condensing
machines, are used to minimize leaks. This is achieved with a system that permits steam leakage
where the gland seals make contact with the shaft, using the pressure differential between them as
an effective seal. A leak-off connection, just before the exterior inactive seals, is designed so steam
reaching that point will run through it instead of the seals.

Gland seals can either be of the segmented carbon ring type, the labyrinth type or a combination of
both. Unless one of these two types is specifically mentioned in this section they will simply be
referred to as “gland seals”.

CARBON RING TYPE GLANDS HAVE EXCELLENT SEALING CAPABILITIES WHEN NEW BUT
ARE SUBJECT TO WEAR. THEY SHOULD BE REPLACED EVERY ONE TO THREE YEARS.
NOTE THAT THEY LOSE EFFECTIVENESS WHEN THE PRESSURE DIFFERENTIAL IS
EXCESSIVE.

Some applications require labyrinth glands. These permit a larger leakage than carbon rings but last
two to three times longer than carbon rings and withstand much higher speeds, pressures and
temperatures.

Many turbines combine both labyrinth and carbon rings. The toughness and durability of labyrinths is
convenient in the highly active interior seals, and the sealing capacity of carbon rings is useful for the
less active outer seals.

Usually, a single leak-off system is enough to seal those turbines operating with moderate
temperatures and pressures. If a more effective seal is necessary, or if the working pressures are
higher, a double leak-off system is used. Refer to the steam P&ID in your manual for the leak-off
piping system on your turbine.

In these cases, leak-off connections closer to the casing (interior leak-offs) are connected to the same
pipe and to a header with a steam pressure of 10-20 PSIG (non-condensing turbine) or 1-5 PSIG (for
condensing machines). Exterior connections are either piped to the atmosphere or to an evacuation
device.

Turbines with a very high first stage pressure sometimes use a triple leak-off connection at the inlet
glands and a double connection at the exhaust.

The interior (high pressure) connection of the inlet is connected to a low pressure stage in the casing.
The middle connection on the inlet connects to the inner stage on the exhaust and to a 10-20 PSIG

16
header for non-condensing equipment or 1-5 PSIG for condensing machines. The exterior
connections are piped to the atmosphere or to an evacuation device.

The best system for any specific application depends upon the pressures involved, the required
efficiency, and the availability of low pressure lines at the installation site.

4.2 Gland seal system: condensing turbines

Condensing turbines are equipped with a gland seal system similar to that of non-condensing
machines, although the function is different. The purpose of the condensing system is to keep
outside air from leaking into the casing since it would reduce the vacuum and cause a loss of power.
The system is not as effective when the machine is standing idle as when it is operating.

The gland seal system works with a supply of 1-5 PSIG steam piped to the leak-off connection. If a
double connection system is used, the sealing steam is connected to both the interior leak-offs.

The exhaust pressure in the casing is always below atmospheric pressure. In the majority of
condensing turbines, the casing pressure is also below atmospheric when operating without load but
rises above atmospheric, in proportion to the increase in power, when a load is added.

When the pressure in the inlet glands rises over the sealing pressure, steam will escape through the
leak-off connection and the need for an external supply or sealing steam will be reduced. As the
amount of steam moving through the leak-off connection rises, the external supply sealing steam
becomes unnecessary. In this case, discharge the excess leak-off to the atmosphere or to some
evacuation device.

The remainder of this section refers to valves and gauges shown on the certified outline and P&ID
drawings and describes the operation of a single leak-off gland seal system.

Under initial (cold start) operation, the gland sealing steam supply valve is opened until the gland seal
pressure gauge indicates approximately 2 PSIG or until steam vapor is noted leaking through the
exhaust end seals.

The valve should then be throttled until the vapor just disappears. This prevents air from leaking into
the casing and spoiling the vacuum.

Unless the turbine has a very low inlet pressure (below about 50 PSIG), the first stage pressure will
be above atmospheric as the turbine approaches full load.

If the high pressure leakage is excessive, vapor will again appear outside the seals. When this vapor
appears, the valve should be closed. If vapor persists, open the gland leak-off valve until the vapor
just disappears or the gauge indicates 1 to 2 PSIG.

A reduction in turbine power demand will cause a reduction in the gland seal pressure as measured
by the gauge. If this pressure drops below 1 PSIG, the gland leak-off valve should be closed until you
obtain the correct pressure.

Note that the objective is to maintain 1-5 PSIG steam pressure in the gland seal piping at all times.
The amount of steam which must be admitted through the gland sealing steam supply valve, or
discharged through the gland leak-off valve, depends on turbine power output; inlet steam
temperature and pressure, exhaust vacuum, and the condition of the shaft seals.

If all of the turbine operating conditions remain fairly constant, and a trained operator checks on the
turbine every 1-2 hours, manual control of both valves may be satisfactory.

17
If the turbine will be subject to rapid and unpredictable changes in steam conditions or power
demand, or if the turbine will not be closely attended, the gland sealing steam supply valve should be
controlled by a pressure regulator.

4.3 Leak-off piping and drains

Where the rotor shaft passes through the turbine casing, packing glands of the segmented carbon
ring or labyrinth type are provided. These have leak-off connections piped to a common point.
FROM THIS POINT, THE CUSTOMER MUST PROVIDE SUITABLE PIPING OF A SIZE
INDICATED ON THE OUTLINE DRAWING.

If it is necessary to run the pipe for a long distance the size should be increased so that back
pressure does not build up on the packing gland. This pipe must slope down from the connection
point to avoid forming a water trap and must not contain a shut-off valve.

A small amount of steam will pass through this line at all times when the turbine is in non-condensing
operation. The amount of steam passing through the line will depend upon the amount of back
pressure.

The leak-off steam is commonly piped to a sewer or open header. If this line becomes partially
clogged, or the back pressure builds up for any reason, steam will blow about the shaft at the packing
gland.

Some machines, especially turbine generators, are equipped with a gland condenser which
condenses the gland leakage as well as steam leaking from other leak-off connections. The
condensate from this gland condenser can be returned to the feedwater system.

Turbines are provided with tapped drain openings which can be piped to a sewer or any other low
point that permits the waste to drain off by gravity. The location of these openings is shown on the
outline drawing.

Drains are provided at other points on the turbine for use in getting rid of excess moisture when
starting up. These drains should be fitted with valves that can be opened when steam is first
admitted to the turbine.

DRAIN VALVES ARE TO BE KEPT CLOSED DURING NORMAL OPERATION. SEE THE
TURBINE OUTLINE DRAWING FOR LOCATION OF THESE DRAINS.

18
 5

ANCILLARY EQUIPMENT

5.1 Governors

A governor is a device used to maintain operating speed in a turbine. The governor is also capable of
varying the operating speed by throttling the inlet valve (also called the governor valve). A governor
can be hydraulic, mechanical, mechanical-hydraulic, or electronic.

Hydraulic governor:
The hydraulic type governor is, in principle, an oil pump driven by the turbine shaft. When speed
increases or decreases, it causes a pressure variation which acts through the governor linkage,
increasing or decreasing the opening of the governor valve.

Mechanical governor:
The mechanical governor works on a system of weights and springs which move according to the
amount of centrifugal force generated by the speed of the shaft. Its movement acts on the governor
valve through linkage and throttles the steam flow.

Mechanical-hydraulic governor:
The mechanical-hydraulic governor combines the advantages of the mechanical and hydraulic type
governors. The mechanism consists of a system of fly-balls and springs which move proportionally to
the centrifugal force exerted by the spinning turbine shaft. With each change in position, they cause
movement of a pilot valve. In turn, the pilot-valve movement permits oil flow to a servo-motor or a
power cylinder which amplifies the fly-ball generated force and throttles the governor valve.

Electronic governor:
The electronic system consists of three parts: sensor, main governor, and actuator. The sensor
measures some operational parameter (speed, inlet pressure, back pressure, etc.) and produces an
electric current proportional to the values of the parameter being monitored.

The main governor receives signals from all the sensors, compares them to a programmed value,
determines the action to be taken by the governor valve, and sends an electrical signal to the
actuator. The actuator receives the signal and answers with the appropriate mechanical movement.
This movement either acts directly on the governor valve or through an oil relay system.

The greatest source of trouble for hydraulic or mechanical-hydraulic governors and actuators is
contaminants and foreign matter in the governor oil. Use only fresh, new oil of high quality. Be sure
that all containers used for governor oil storage are clean.

Foaming or the formation of sludge may occur if the oil is allowed to break down or oxidize, resulting
in excessive wearing of plungers, bushings, gear, etc. It may also cause parts to stick or seize.
Change the governor oil whenever it appears to be dirty or breaking down from contaminants or
excessive temperatures.

When changing governor oil, drain it while it is hot, flush the governor oil system with the lightest
grade of the same type oil, and refill with fresh oil of proper viscosity.

The time interval between governor oil changes depends on many factors. Some of those factors
include the type of service, operating temperatures, quality and type of oil, etc. Read and follow the
manufacturer’s recommendations on governor operation and maintenance.

19
5.2 Governor Valve

The governor valve is the device which controls the performance output of the turbine. The typical
control valve for a single valve turbine is a fully characterized, double seated, pressure balanced
valve constructed of stainless steel. The governor valve is actuated directly or indirectly by the speed
governor.

For multi-valve turbines the valves are either of the poppet type or the double seated balanced type of
four, five or six valve design, depending on the steam chest selection. All multi-valves are actuated
indirectly by the speed governor through an oil relay system.

5.3 Trip systems

A trip system refers to the device that stops the turbine in the event certain operational parameters
reach unsafe levels. Normally, these minimum parameters are overspeed, low oil pressure, and high
oil temperature. The trip system can be designed to act upon any operational condition.

A quick acting steam shut-off valve is supplied. The linkage system on these valves has been
provided with a small lever for manual operation and an automatic trip system. The automatic trip
can be mechanical (by means of springs and linkages), hydraulic (by means of oil pressure),
electronic (by means of electrical signals), hydraulic-electric (by means of solenoid valve that
discharges oil pressure), or pneumatic (by means of air pressure).

All trip systems are optional with the exception of the OVERSPEED SYSTEM WHICH IS
MANDATORY.

These overspeed systems can consist of an overspeed governor, incorporating a bolt equipped with a
weight and a spring, or an independent electronic system. With the mechanical overspeed bolt, when
the machine overspeeds, the centrifugal force overcomes the spring’s load and causes the overspeed
plunger to extend out of the shaft, striking the linkage that closes the trip valve. With the independent
electronic overspeed, shaft speed is monitored by magnetic pick-ups and trips the oil solenoid when
shaft speed reaches a set point. The operation of these systems should be checked periodically (at
least once every month) by slowly accelerating the machine to trip speed.

Butterfly type trip valves work by mechanical means and integrated trip and throttle valves usually trip
by means of oil pressure. The advantage of this second type is that it can be connected directly to
the lubrication piping and, in case the oil pressure drops, it can act automatically.

Dresser-Rand recommends using the hand trip lever every time the operation is stopped, since in
doing so the entire emergency trip system (with the exception of the overspeed governor) is
exercised.

5.4 Ring oil Lubrication

Oil requirements for ring oiled bearings is ISO 68. Brass oil rings running on the turbine shaft pick
up oil from reservoirs in the bearing housings. As the shaft and oil rings rotate together, oil flows from
oil rings onto the shaft, ultimately flowing into the bearings, providing lubrication. The oil level within
bearing housings must be maintained at a sufficient level to allow the oil rings to run in the oil. An oil
level that is too high results in oil leakage past the shaft seals. Oil rings cease to rotate sufficiently
when the shaft runs below 900 RPM, no longer providing adequate lubrication. Therefore, the turbine
should not be run at speeds less than 900 RPM.

CAUTION

DO NOT RUN turbines equipped with oil ring lubrication at speeds LESS
THAN 900 RPM. The OIL RINGS WILL NOT OPERATE CORRECTLY at
these speeds, causing BEARING FAILURE due to lack of lubrication.

20
Cooling of the bearing oil is accomplished by water jackets integral to the bearing housings.

Refer to the certified outline drawing in this manual for the location of cooling water connections on
bearing housings.

Cooling water should be piped into one of the lower connections and out from the upper connection
on the opposite side. If interconnection of water jackets on the two bearing housings is desired,
connect the outlet of the governor end bearing housing to the inlet of the drive end bearing housing.
All unused bearing housing connections should remain plugged.

Valves should be included in the cooling water piping to control the flow of water and allow it to be
shut off. The ideal system would employ two valves—one upstream of the bearing housing, acting as
a shut-off valve, and one downstream to control flow. This arrangement ensures that water jackets
are filled with water and allows water to be shut off without disturbing the flow adjustment. If one
valve is used, it should be downstream of the bearing housings.

Flow should be adjusted to maintain bearing oil sump temperature in the normal range shown in the
table below.

Recommended Bearing Oil Sump and Metal Temperatures

Bearing Oil Sump Temperature Bearing Metal Temperature

Operating Status °F °C °F °C
Normal Operation 130-180 54-82 150-200 66-93
Alarm 200 93 210 99
Trip 210 99 220 104

CAUTION

Do not allow COOLING WATER to COOL BEARING OIL SUMP

TEMPERATURE TO BELOW 130°F (54°C), as this may interfere with the
action of the oil rings or cause ATMOSPHERIC MOISTURE to
CONDENSE in the oil reservoir.

Cooling water for bearing housings must meet the following specifications.
Flow rate (per housing): 1 gpm (3.5 l/min)
(if interconnecting pipe used): 2 gpm (7.0 l/min)
Maximum inlet pressure: 150 PSIG (1035 kPag)
Maximum inlet temperature 90°F (32°C)

Constant Level Oiler

Turbines lubricated with oil rings are equipped with constant level oilers. The purpose of these oilers
is to maintain the correct oil level in the bearing housings. Instructions for Constant Level Oilers may
be found in this manual.

Oil Levels

Oil levels that should be maintained by proper adjustment of constant level oilers. The oil level gauge
on the side of the bearing housing indicates the oil level. A mark inscribed on the lower-half bearing
housing indicates the proper oil level.

21
Maintenance/Oil Changes

Oil levels in both bearing housings and the governor should be checked daily.

Low point drains in the bearing housing should be checked weekly for water.

Establish an oil change frequency based on oil tests. Otherwise, oil in bearing housings should be
changed monthly; or earlier, if there is reason to believe that the oil has been contaminated with
water, dirt, or by overheating.

CAUTION

The presence of oil in the constant level oilers does not necessarily mean
that oil in the bearing housings is at the proper level.

CAUTION

CLEANLINESS is ESSENTIAL for long and trouble free service from

BEARINGS and the GOVERNOR. Care must be taken to ensure that no
foreign material enters bearing housings, the governor, or constant level
oilers when performing maintenance, checking oil, adding oil, or making
adjustments.

5.5 Pressure Lubrication

Pressure lubrication is used on all Murray turbines. The system consists of a main oil pump powered
by a driving source such as the turbine shaft, a gear shaft or a motor.

Pressure relief valves are used in the pressure lubricating system to control pressures through the oil
filter, oil cooler, piping and optional auxiliary oil pump.

Always keep the proper oil level in the sight gauge. The system must supply continuous lubrication to
all contact surfaces. THE OIL LEVEL SHOULD BE CHECKED AT LEAST ONCE A DAY OR
EVERY 8 HOURS IF THE TURBINE OPERATES 24 HOURS A DAY.

Normally, a small amount of oil (of the recommended type and viscosity) should be added between oil
changes to maintain the proper oil level.

If an elevation in the oil level is observed in the sight gauge when no oil has been added, water is
probably collecting in the oil. If an abnormal decrease is observed, there are oil leaks in the system.
If an unexplained rise or drop in oil level is observed in the sight gauge, investigate immediately and
stop the machinery if necessary.

The tendency of oil to oxidize and deteriorate increases with temperature. A rise in oil temperature
also decreases viscosity which progressively lowers the ability of oil to lubricate machinery properly.

Pressure lubrication systems are equipped with external oil coolers. The supply of water to these
coolers should be opened at start-up and kept open through normal operation to maintain 110-120°F
oil supply to the bearings.

22
The operator should frequently observe the temperatures at the inlet and outlet of the oil cooler. Any
drastic change should be investigated. Keeping a record of temperatures is advisable since it
provides a good base for comparison.

Take reading from the pressure gauges every one or two hours and investigate any change (gradual
or sudden). The most frequently encountered difficulty is pressure drop, and the most common
causes are clogged oil filter, worn pump, faulty relief valves, insufficient oil in the reservoirs, clogged
piping, entrained air, and temperature elevation.

The most common sources of oil contamination are impurities picked up during storage, shipping, or
adding of the lubricant, dirt in the entrained air, water in the oil reservoirs, leaks in the oil cooler, or
condensation of gland leakage.

Always use a strainer when adding oil to the systems and cover the fill connection when finished.
Make sure the gland system works properly. For details, see Section 4 on Steam Seals.

Water gives oil a milky appearance, and it has a tendency to settle at the bottom of the reservoir
when the turbine is not running. If there is any reason to suspect water in the oil, open the reservoir
drain slightly. If water is present, it will be the first thing to come out of the drain.

The oil in turbines lacking very large, deep reservoirs should be inspected while the equipment is
standing idle. If the turbine operates constantly and has a small reservoir, take a small sample of oil
from the reservoir and let it sit a few hours. If any water is present it will settle to the bottom of the
container.

The probability of oil contamination will increase if:

• Gland seals are allowed to become excessively worn, if obstructions are allowed to develop in
leak-off piping

• If the turbine is allowed to stand idle with back pressure on the casing

• If there is too much sealing pressure on a condensing turbine.

Care should be taken to avoid these conditions.

TURBINES OPERATING OUTSIDE WITHOUT ANY INSULATION RUN A HIGHER RISK OF

HAVING THE OIL CONTAMINATED WITH WATER AND SHOULD BE CHECKED MORE
FREQUENTLY.

When oil is agitated it mixes with air and produces foam. Foam inhibits the ability of oil to lubricate
properly by reducing the oil pressure (which could result in hydraulic governor malfunction), excessive

23
wear of moving parts, rapid oil deterioration and oxidation, and loss of oil through seepage. The
problem is usually solved with oil additives, lowering water flow to the cooler and circulating the oil at
a slightly higher (not to exceed 120°F) temperature, lowering the oil circulation pressure (not less than
13 PSIG), and maintaining the proper oil level.

Sludge impairs oil circulation and causes oil temperature elevation, which accelerates oxidation and
reduces lubricant life and causes possible malfunction of hydraulic governors and oil relays. Any
sludge should be removed as soon as it is found. Sludge formation can be minimized by using high
quality oil and keeping the system free of impurities.

5.6 Lube oil flushing

Flushing the oil circulation system is recommended before starting a new turbine (or one that has
been in storage for a long time). On a new turbine, remove the mylar protection that stabilizes the
shaft during shipment. To do this, remove the upper half of the bearing housing, remove the upper
half of the bearing and remove the two pieces of mylar protection from the shaft. This must be done
at both the steam and exhaust end bearings. Leave the upper halves of both bearings out to allow for
more volume of oil to flow during the flush. Reseal the upper bearing housing cover and replace the
bolting.

Once the mylar has been removed and you are ready to begin the oil flushing procedure, the
following steps should be followed:

1. Bump the aux. lube oil pump motor to assure that the pump is rotating in the proper direction to
achieve pressure.
2. Remove the supply connection to the hydraulic actuator (if supplied with hydraulic actuator) and
plug the line to prevent flow of oil into the actuator.
3. Install 100 mesh plain weave (.0059 opening) screen mesh ahead of all bearing cases (steam,
thrust if separate, exhaust, and any driven equipment being supplied of the oil system).
4. Start up aux. oil pump and run the system for two hours. Shut down pump and check all
screens for particles. Screens should not have any particles bigger than .01 inch in diameter
and show random distribution. No metallic particles should be present. Flushing should
continue until screens show no more than 6 non-metallic particles.
5. Replace screens with new ones and continue flushing in one-hour intervals until no metallic
particles and no more than 6 non-metallic particles are present on any of the screens.
6. Once clean screens are present, remove all screens, bleed and reconnect the actuator line,
service the turbine bearings and replace them in the bearing housing. Housings must be
cleaned and resealed with Tite-Seal to prevent oil leaks at the case split line.
7. Check the condition and cleanliness of the oil filters furnished on the set and replace them with
new filters if needed before continuing with the start up.

5.7 Lubricating oil recommendations (100°F)

The basic turbine and gear oil for new units is a #32 which should exhibit an average viscosity of 162
SSU @ 100°F. For turbines with speed reduction gears (prior to Serial Number 5070) the oil is a #68
which has an average viscosity of 319 SSU @ 100°F. If there are any doubts about a particular oil for
turbine use, consult the Customer Service Department at Dresser-Rand.

Direct connected prior to 1957 140-200 SSU (ISO 32)

Direct connected over 6000 RPM since 1957 140-200 SSU (ISO 32)
Direct connected serial #4740 and over 140-200 SSU (ISO 32)
Direct connected below 6000 RPM since 1957 to serial #4740 250-350 SSU
Geared (MURRAY gears) 250-350 SSU
Geared (other manufacturers) Per gear nameplate
Ring Oiled 315-355 SSU (ISO 68)

24
5.8 Bearings

Murray turbine bearings perform two functions. The journal bearings support the rotor’s weight and
the thrust bearings protect the turbine against any type of excessive axial displacement. These
bearings are lubricated by a pressurized lubrication system.

All of Murray’s journal bearings are of the hydro-dynamic type, which means they operate by means
of an oil film between the contact surfaces to eliminate metal-to-metal contact. They can be straight
sleeves, pressure dam, or tilting pad types.

The pressure dam type is used in higher speed applications and is equipped with an oil pocket in the
upper half that eliminates oil whirls by creating an oil wedge that presses down on the journals.
When installing pressure dam bearings, always remember that they are installed with the grooved
part at the top and the direction arrow pointing in the direction of rotation.

Tilting pad journal bearings are used in applications that require additional stability (dampening
effect). The seat of these bearings can be placed in any of three ways – fixed seat, spherical seat,
and a cylindrical bearing in a spherical seat. The fixed seat holds the bearing firmly without play,
whereas the spherical seat permits a certain amount of play to compensate for various cold condition
alignment offsets. The cylindrical bearing with a spherical features the self-alignment of spherical
seats plus the convenience of replaceable sleeve segments.

Murray thrust bearings can be thrust collars, ball bearings, or multi-segmented tilting pad type. Thrust
collars are simply two rings, one at each side of the journal bearing, holding the shaft in place. Ball
bearings are used in applications under 6,000 RPM where space permits. They should be replaced
each 20,000 hours or when indicated by vibrations. The multi-segmented type is self-adjusting so
that the thrust is equally divided among all the shoes on either side of the collar.

THE ROTOR ASSEMBLY DRAWING IN THE INSTRUCTION MANUAL PROVIDES THE PROPER
BEARING CLEARANCE FOR EACH MACHINE.

5.9 Couplings

There are many types of flexible couplings on the market which are compatible with Murray turbines.
Among these are the gear, rubber bushing, and various steel spring types. Never use a coupling
which will transmit end thrust as this could overload the thrust bearings.

Lubricated type couplings should be inspected periodically to ensure that they contain sufficient
lubricant. Prolonged operation of these types without lubricant may result in rusting or freezing.
Manufacturer’s recommendations should be strictly followed.

Generally, the couplings in Murray turbines are mounted by means of a shrink fit using a key guide.
In special cases, or by customer request, a hydraulic fit is used. This is an arrangement that requires
special tools. Consult your assembly drawing to see if this is applicable.

5.10 Handvalves

Mechanical drive turbines and those driving small generators are commonly provided with hand
operated nozzle valves for one or more purposes. Closing a hand valve reduces the number of
steam nozzles being fed, thereby admitting less steam to the turbine and requiring the governor to
open the governor valve wider to increase the inlet pressure on the remaining nozzles.

The inlet pressure to the nozzles can usually be increased to within 95% of the throttle pressure
without loss in speed. When operating this high level inlet pressure, the turbine lacks reserve

25
capacity to handle an increase in load or to carry the present load with lower steam pressure or
higher back pressure.

Higher inlet pressure decreases steam consumption through improved efficiency. If a hand valve is
opened instead of closed, greater potential capacity is available, but the steam consumption is
increased.

The purpose of hand valves is to provide added efficiency when more than one load or steam
condition is anticipated. For the specific use of hand valves, refer to the sheet of operating
conditions.

5.11 Sentinel warning valve

Almost all turbines are provided with a sentinel warning valve in the exhaust casing. This valve is too
small to be considered a relief valve. Its purpose is to warn the operator of excessive pressure in the
turbine casing. It should be tested each time a general inspection is made to see that it is in
operating condition. This valve should be set to open at 10 to 15 PSIG above the normal back
pressure in non-condensing turbines.

For condensing turbines, the sentinel valve is usually set to open at 5 PSIG. Should the valve leak
under normal back pressure, it should be opened a few times by hand to allow any foreign material
which may have collected on the seat to be blown out. If this fails to correct the leakage, the seats
may be ground in or the entire valve replaced. DO NOT, UNDER ANY CIRCUMSTANCES, PIPE
THE DISCHARGE FROM THE SENTINEL VALVE AWAY FROM THE TURBINE.

5.12 Steam strainers

Some turbines are supplied with separate steam strainers for mounting in the steam line. These have
a corrosion resistant element which can be removed for cleaning without dismantling the steam
piping. Steam line strainers should be inspected periodically, and cleaned if necessary, to avoid
excessive steam pressure drop due to clogged strainer screens. Large pressure drops may not only
reduce the turbine load carrying capacity, but may result in a rupture of the strainer element.

On some turbines a built-in type of strainer is supplied. Built-in strainers should also be inspected
and cleaned periodically and checked for possible damage. A steam strainer affords some measure
of protection against foreign material passing through the nozzles and blades, but it cannot be
expected to stop heavy objects which move through the steam line at high velocity.

Pieces of weld metal, large pieces of scale, nuts, and other materials are commonly present in newly
erected steam lines. For that reason it is NECESSARY TO EMPHASIZE THE IMPORTANCE OF
BLOWING OUT ALL STEAM LINES WITH LIVE STEAM BEFORE CONNECTING THE TURBINE.
FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE STRAINER OR MORE SERIOUS
DAMAGE SUCH AS BENT OR FAILED BLADES.

5.13 Gland evacuation equipment

This equipment can be used on high backpressure applications, those turbines operating with a high
pressure differential across the glands, and those which must operate for long periods of time
between shutdowns (some low pressure turbines also use these devices).

These devices are piped to the outer leak-off connections of the glands. They create a slight vacuum
on the outer leak-off areas, assuring that leakage will leave through leak-off piping and not past
inactive seals.

26
The simplest gland evacuating device is the water eductor. It creates a low pressure area by means
of water flowing through a nozzle. Its discharge (steam, air and water) is evacuated through the
sewers without contaminating the working area with escaped steam. These devices have limited
capacity and can only be used in low leak-off flow applications. Note that all of the water and steam
is lost in the sewers and cannot be recovered.

Another common device is the gland condenser and ejector. The gland condenser is a shell-and-
tube type heat exchanger in which cooling water is used to condense steam leakage from the glands.
The ejector is a steam nozzle which creates a low pressure area to remove any air which has leaked
into the system and thus maintains the vacuum in the leak-off areas.

These devices are available for all types of leak-off flows, large or small. The condensed leakage
steam and cooling water can be recovered and returned to the boiler. Note that the condenser tubes
and ejector both require periodic cleaning.

In a few cases, a motor-driven vacuum pump is used for gland evacuation. Vacuum pumps can be
selected for small or large gland leakage flows. They do not discharge steam into the turbine room,
and they require neither cooling water nor moving steam. Vacuum pumps are expensive to buy and
they require electricity. Like all rotating machines, they require maintenance, and should be kept in
use during turbine operation.

5.14 Condensing multi-stage turbine

The operator should be familiar with Section 2.1 (Top Exhaust), Section 4.2 (Gland Seal Systems:
Condensing Turbines). Condensing multi-stage turbines have relatively long and heavy rotors. They
are usually of the “flexible shaft” design. This means that the first critical speed or resonant rotor
frequency is normally below the minimum operating speed.

Operating a turbine at its critical speed can result in destructive vibration, so it is important to pass
through the critical speed quickly before such vibration builds up. The critical speed commonly
covers a band of 100-200 RPM above and below the critical speed indicated on the turbine
nameplate.

In starting multi-stage condensing turbines, the following precautions must be observed in addition to
the standard operating procedure as outlined under section 6.

If the turbine is warm because of a leaking throttle valve, it is possible that the shaft has taken a bow
because of heat distortion. It is returned to its normal shape by rotating slowly at 200-300 RPM for
30-60 minutes with the auxiliary oil pump in operation. If no auxiliary pump is available the initial
speed must be enough to establish 3-5 PSIG oil pressure.

Even if the throttle valve has not leaked, it is advisable to operate at the lowest speed that will
produce oil pressure for the turbine and driven machine for about 15-20 minutes. After this, the
turbine is accelerated moderately until near critical speed, and then accelerated rapidly through that
range. Once the turbine has passed through the critical range, acceleration should be more
moderate up to minimum control speed. After the governor takes over, the throttle valve can be fully
opened. As soon as full vacuum is established, the turbine is ready for load.

27
 6

OPERATING THE TURBINE

6.1 Operation

BEFORE ATTEMPTING TO OPERATE THE TURBINE, BE SURE THAT YOU HAVE READ AND
UNDERSTAND ALL THE INSTRUCTIONS IN THIS MANUAL. When placing a newly installed
turbine in operation the operator should proceed with caution and check all conditions carefully.

To protect your turbine during the starting operation, a man should be stationed at the emergency trip
lever at all times to stop the machine promptly if problems occur. Although Murray turbines are
adjusted at the factory, changes can occur during shipping and when coupled to a load.

Since normal operating speed of the turbine is maintained by the main governor, and the turbine is
protected against possible damage due to excessive speed by the emergency governor mechanism,
the operator must familiarize himself with the operation of these features before starting the turbine.

6.2 Condensing, Mechanical Governor

1. Read this instruction manual thoroughly.

2. Check oil reservoir or, if ring oil lubrication is used, check bearing oil reservoirs to be sure
there is the correct amount of oil.

3. Thoroughly drain condensate from steam supply line.

4. Open drain valves on turbine casing and gland seal system. Start Auxiliary oil pump if
provided.

5. Set solenoid trip, turbine trip valve and overspeed trip mechanism.

6. Open the exhaust shut-off valve, if installed.

7. Start cooling water flow to condenser.

8. Warm up turbine casing with drains open by slowly opening throttle valve or bypass valve, if
one is installed, to establish a “slow roll” speed. Do not exceed approximate speed range of
500-1000 RPM. Operate at this speed in accordance with the time specified in Time vs.
Speed Diagram on next page. NOTE: IF RING OIL LUBRICATION IS USED, MAINTAIN
IDLE SPEED ABOVE 900 RPM.

9. When casing is warm, close all casing drains after fully draining condensate. If a sub-
atmospheric casing drain system is installed, check that it is drained and that atmospheric
vents are closed and drains to condenser and from turbine are open.

10. Place condenser in operation in accordance with manufacturer’s instructions and set
governor at minimum speed.

11. Open sealing steam line to establish approximately 1 PSIG on steam seal system. Reduce
pressure if steam blows from glands.

12. Check turbine for proper operation of lubrication system, for vibration, or for any unusual
noise or condition. In the event of any abnormal condition, investigate immediately and shut
down if necessary.

28
 Min. Gov.
Turbine Speed

Idle

SRT Time

A period of slow roll at idle speed is required before the turbine can be run continuously. After slow
roll, the turbine speed can be increased to normal operating speed. Slow roll is shown in the above
diagram as a solid line. The dotted line shows where the turbine speed is ramped up to minimum
governor speed manually or with the electronic governor.

The amount of time required to slow roll at idle speed varies, depending on the inlet steam
temperature and the number of stages in the turbine. Use the following formula to determine the
minimum slow roll time required:

Ti-350
SRT = 20+ +Ns
50

where SRT = Slow Roll Time in minutes

Ti = Inlet Temperature in °F
Ns = Number of Turbine Stages

Example: Consider an R2GD3 turbine with an inlet temperature of 750°F.

So we know that Ti = 750, Ns = 4

750-350
SRT = 20+ +4=32
50

Therefore, this turbine should slow roll for a minimum of 32 minutes.

29
 4900rpm - 5500rpm critical speed
Auto Ramping from 1000 rpm to 9230
rpm
1000rpm to 9230rpm 9230 rpm

13. Slowly open throttle valve to bring turbine to minimum speed, going through critical speed
quite rapidly. Make sure turbine governor takes control and continues to control. Open
throttle fully, making sure governor maintains control.

CAUTION: DO NOT OPERATE TURBINE AT OR NEAR CRITICAL SPEED SHOWN ON

NAMEPLATE.

14. Again, check general operation, oil pressures and temperatures, casing drain tank level,
vibration and noise. IN THE EVENT OF ANY ABNORMAL CONDITION, INVESTIGATE
IMMEDIATELY AND SHUT DOWN IF NECESSARY. Adjust water flow to oil cooler.
Maintain approximately 110-120°F oil temperature leaving cooler. If ring oil lubrication is
used, adjust water flow to maintain oil reservoir temperature of 130-180°F

15. Check to see that condenser system is operating properly.

16. Check gland seal system. Under some load conditions there will be sufficient leakage of
steam from the high pressure or inlet end of turbine to seal the low pressure end. The steam
seal valve and the gland leak-off line valve is to be adjusted as required to prevent gland blow.

17. Adjust to desired speed and apply load.

18. In the event of any abnormal condition, investigate immediately and shut down if necessary.

19. To shut down turbine remove load slowly, checking to see that governor maintains control.
stop turbine by means of hand or solenoid trip. If unit is provided with an auxiliary oil pump,
operate pump for a minimum of thirty minutes after stopping or until the shaft is cool. Close
inlet stop valve. Shut down auxiliary equipment as required, open casing drains, shut off
sealing steam.

6.3 Precautions

If the turbine is showing excessive vibration, bring it to a stop immediately and recheck the coupling
and shaft alignment and other possible causes. Check all bearings.

If any other abnormal operating behavior becomes evident, stop the turbine and determine the cause
before putting the unit back into operation.

For pressure feed lubrication, the oil pressure should be observed frequently until the turbine has
been operated for several days as failure of oil pressure can result in extensive damage. The oil
reservoirs should be maintained at the proper level using oil of the recommended grade.

When starting a turbine with cold oil, the oil pressure will be somewhat higher than when the oil
reaches operating temperature. This is a natural condition due to the change in oil viscosity with
temperature. ANY ADJUSTMENT TO OIL PRESSURE SHOULD BE MADE WITH THE OIL AT
OPERATING TEMPERATURE.

By recording oil pressures and temperatures on the turbine log sheet, the development of conditions
which could damage the machine will be more evident. Refer to the section on lubrication for other
important factors (see Sec. 5.4).

Since all Murray turbines are provided with an overspeed trip device actuating either an emergency
stop valve or a trip throttle valve, this device should be tested at least once every month.
The effectiveness of this device depends upon it being properly maintained. It is a good practice to
stop the unit by means of the hand trip whenever it becomes necessary to shutdown.
30
 7

MAINTENANCE AND INSPECTION

7.1 Maintenance and inspection program

USE THIS SECTION TO STRUCTURE A REGULAR PROGRAM OF INSPECTION AND

MAINTENANCE.

Murray turbines are manufactured in various frame sizes and model numbers. Special features plus
variations in local conditions make it impossible to standardize on a general maintenance schedule
that would apply equally to all situations. THEREFORE, THIS SECTION IS DESIGNED TO HELP
OPERATORS BEGIN AND CUSTOMIZE A MAINTENANCE PROGRAM AND HELP ESTABLISH
GUIDELINES FOR PERIODIC INSPECTIONS AND MAINTENANCE.

Monthly inspection

• Check the overspeed trip by accelerating the turbine to trip speed.

Quarterly (3 months) inspection

• Clean all linkage systems and inspect for wear. Clean and oil or grease all the moving parts
(fulcrum points). For units with Inlet operating temperatures above 500deg F a high temperature
grease should be used for lubrication on linkage parts. (DuPont Krytox GPL407, Bostic Never-
Seez #235210 NHTC14 or equivalent)

Six month inspection

• Remove and inspect the bearings. Inspect the radial contact surfaces (journal) and the axial
contact surfaces (thrust faces). Make sure that there are no signs of overheating, excessive wear
(including dents, grooves or tears), or dirt.

• Check the effectiveness of all drains.

• Disconnect and separate couplings. Remove all grease and sludge and then flush. Inspect the
wear on the hub and cover teeth. Then dry and replenish with new, high quality grease.

• CHECK THE SENTINEL AND RELIEF VALVES TO ENSURE THAT THEY ARE
OPERATIONAL. The relief valve should start opening when the sentinel valve opens and should
completely open when the pressure in the casing is 10% above normal pressure.

• Operate the turbine without a load and inspect governor operation and vibrations.

Yearly inspection

• Drain the governor’s oil, if applicable, while it is hot; flush the governor’s pump clean with the
lightest grade of the same oil; replace with high quality oil of the recommended grade and
viscosity.

• Remove and clean governor valve and internal steam strainer. Make sure there are no leaks.

• In pressure lubricated turbines, drain and clean reservoirs. In machines with a large reservoir,
where the cost of oil is a consideration, it may be convenient to check a sample of the oil before
deciding to change it.

31
• Replace oil filters; replace oil with one of recommended viscosity and grade.

• If the equipment is insured, the insuring company’s inspector should be notified of the yearly
inspection so that he can be present. In many cases, the services of Dresser-Rand’ experienced
service personnel are used to ensure maximum efficiency.

THE TURBINE INTERNALS MUST BE PERIODICALLY INSPECTED. THE FREQUENCY OF

INSPECTION DEPENDS ON STEAM CONDITIONS AND OPERATION BUT SHOULD NOT
EXCEED 3 YEARS.

THE PROGRAM DESCRIBED IN THE ABOVE SECTION IS A LIST OF RECOMMENDATIONS

ONLY. IT MAY BE NECESSARY TO INSPECT MORE FREQUENTLY IF PROBLEMS ARISE
BETWEEN REGULAR INSPECTION PERIODS.

7.2 Internal inspection

To perform the thorough periodic inspections recommended by Dresser-Rand, it will be necessary to

remove the turbine cover. Housed under that cover are diaphragms, the turbine rotor, nozzle block,
shaft seals, the stationary blade segment, and the casing interior.

Inspection of other parts, such as bearings, governor and linkage, oil pump drive assembly, governor
valve and trip valve, can be accomplished without casing cover removal.

Where turbines have a top exhaust, the inspection procedure is more involved since the exhaust pipe
must first be removed to provide the necessary free space above the turbine. The casing cover can
then be removed by the following procedure:

It should be remembered that the casing assembly is a pressure tight vessel and that all joints are
necessarily sealed to prevent steam leakage. These include the main horizontal casing flange, gland
case splits and vertical surfaces.

These joints have been kept in contact by the bolts while under prolonged exposure to heat and
moisture. Even though joint compounds have been used at the factory which assist sealing and help
prevent sticking, it is to be expected that more or less sticking may occur from corrosion at one or
more of these points. IT IS THEREFORE NECESSARY TO PROCEED WITH CARE IN ORDER TO
AVOID DAMAGE TO THE ROTOR AND OTHER STATIONARY PARTS.

First, remove sheet metal covering, if provided, insulation and piping as required, then all horizontal
joint bolts. There are four tapped holes in the horizontal flange. These are provided for the use of
jack-bolts in order to “break” the main casing joint.

Insert bolts and apply reasonable torque to part the joint. In some cases, it may be necessary to use
penetrating oil and tap on the casing barrel while jack-bolts are fully tightened. After the joint
separates, continue to raise the casing cover with the jack-bolts. The rotor must remain free and
bearing caps must not lift as the cover is raised.

ROTATING THE SHAFT WHILE RAISING THE COVER WILL ASSURE THAT THE ROTOR IS
NOT IN CONTACT WITH ANY PARTS BEING RAISED. If the rotor rises with the cover, it indicates
that either the lower half of a diaphragm or a carbon ring retaining plate is rising
with the cover. This situation is brought about by diaphragm halves sticking together in Type “K” or
“R” turbines (while free in the base) or by retainer plates sticking in the casing cover and being free in
the base. In either case, the cover should be lifted with the jack-bolts only until all the clearance (1/6
to 1/8 inch) is taken up and the rotor starts to rise. Do not lift beyond this point, but retract two
diagonally opposite jack-bolts and rock the cover back and forth.

32
Try to determine where the sticking is occurring so that if the rocking does not release the stuck joint,
the use of penetrating oil and tapping on the outside of the casing will. DO NOT USE WEDGES OR
PRY BARS BETWEEN THE JOINT AS THIS WILL DAMAGE THE SURFACE AND CAUSE
LEAKAGE.

If there is persistent sticking of these parts, considerable care must be exercised to free them.
Tapping and rocking as described above should be continued; possibly tapping directly on the
circumference of the diaphragm or retainer plate by inserting a flat bar between the casing flanges
(against the diaphragm or plate) and tapping on the exposed end.

After the parts are free, a chain hoist can be used to remove cover and rotor. In the case of Type “U”
turbines, any sticking should be limited to the carbon ring retainer plates. The lower diaphragm
portion cannot rise and the upper portion is fastened to it.

No difficulty should be encountered in lifting the casing cover. The packing cases employ stainless
steel carbon ring retainer plates. Should the plates stick in the packing case, screw an eyebolt in the
horizontal flange and impose a lift strain by means of a hand operated chain hoist while tapping on
the upper portion of the packing case near the centerline.

If it is found that any retainer plates are stuck in the lower portion, these should be freed up with
penetrating oil. After the retainer plates are all free, the rotor, with retainer plates, may be lifted out
with a chain hoist.

The diaphragms are removed by rolling out, assisted by pulling on a clamp fastened on one corner
with a chain hoist. It may be necessary to free-up the diaphragms with penetrating oil before they can
be rolled out.

Before re-assembly, the pressure joints must be completely cleaned to the bare metal. The joints
must then be re-coated with sealing compound using a type which will not harden in service. Murray
joint compound is available for this purpose and will not “freeze” the joints.

The joint compound is also suitable as an anti-seize compound or pipe thread sealant. The
compound must be kept absolutely clean and free of metal particles which might interfere with proper
sealing.

Apply a light even coat, leaving about ¼ inch of the joint surface on the inside and outside uncoated
to avoid surplus squeeze-out. Coat only the casing joints and the packing case joints of bolted type
packing case. Do not apply closer than ¼ inch to carbon rings.

Do not coat diaphragm joints or grooves. Bearing caps should not be sealed with high temperature
joint compound. Instead, use a material intended for oil tight joints such as “Tite-Seal” or a similar
non-hardening Teflon-based paste compound.

CHECK THE CASING INTERIOR FOR FOREIGN MATERIAL BEFORE CLOSING.

The casing cover should be carefully lowered. If it appears to “hang up”, use a slight rocking motion
to assist proper mating of parts. Use the dowels on guide rods to assist positioning. The bolting
should be tightened uniformly, in about three stages, finally achieving approximately uniform torque
on all bolts of the same size. If the joint has been properly serviced, it should be as tight as before
the inspection.

33
 8

SPARE PARTS & FIELD SERVICE

8.1 Spare Parts

When ordering repair, replacement, or spare parts there is certain specific information Dresser-Rand
must have to properly identify the parts required. Omitting that information from your order may
cause a delay until the information is made available to Dresser-Rand’ Parts department. Such
delays can easily be avoided if reasonable care is taken to include the following information on all
orders.

• Turbine serial number (located on the turbine’s nameplate or coupling end of the shaft).

• Bill of material number, or assembly drawing number, along with item number shown on the bill of
material, or the assembly drawing, identifying the part required.

• Name of part as shown on the bill of material.

• Quantity required.

Example:
1 part #OA1157 Item 6, Spherical Rod
1 part #4A0377 Item 6, Spherical Rod End

#OA1157 refers to the bill of material, whereas #4A0377 refers to the assembly drawing number.
Either number may be used by Dresser-Rand’ order department in identifying your requirements.

Anticipate part needs in advance when possible. Dresser-Rand recognizes that anticipation of
repairs is not always possible and will make every reasonable effort to meet the needs of the client.
Since some spare parts require manufacturing time, it is worth emphasizing, “ANTICIPATE REPAIR
REQUIREMENTS WHEREVER POSSIBLE AND ORDER PARTS IN ADVANCE”.

8.2 Field Service

Dresser-Rand maintains a staff of trained and experienced field personnel available for installation,
inspection and repair work.

The services of factory servicemen are not included in the purchase price of Murray turbines unless
requested in the proposal stage and specifically mentioned in the contract or purchase order.

Customers not experienced with the installation or operation of steam turbines may wish to utilize the
experience of Dresser-Rand’ factory-trained field personnel on a per diem plus expenses basis.

To have a factory-trained technician sent to your job-site, simply contact your local Dresser-Rand
office or our manufacturing facility in Burlington, Iowa at (319) 753-5431. Provide a completed
purchase order and the serial number of the unit involved. A short description of the problem will
allow the Dresser-Rand technician to evaluate special tools and/or parts required. Two weeks’ notice
is considered standard operating procedure for all routinely scheduled inspections or maintenance.

34
 STEAM PURITY/TURBINE DEPOSITS

9.1 Introduction

It is generally recognized that the performance and reliability of a steam turbine can be adversely
affected by the admission of contaminated steam. When contaminants enter the turbine with the
steam supply, the usual result is the accumulation of deposits, either inert or highly reactive,
depending on the contaminants present. If the contaminants are reactive, they can cause serious
damage by corrosive attack on the turbine materials.

To avoid these deposits, adequate boiler water chemistry control and other precautions are required
along with the need for constant surveillance during operation and inspections. When deposits or
material attack are noted during inspections, investigations into the nature and origin of contaminants
should be conducted and a program for corrective action begun

9.2 Steam purity

Deposits and harmful ions come from additive chemical elements in boiler feedwater. Make-up water
for many steam systems utilizing Murray turbines is industrial grade water which contains dissolved
and suspended contaminants which must be removed prior to use in the steam system.

To avoid the likelihood of adverse effects from deposits and harmful ions, limits shown in Table 9.2.1
are established for Murray steam turbines. These limits are based on operating history and
recommendations from various consultants. Their maintenance will ensure protection of the turbine.
WARRANTY MAY BE VOID IN THE EVENT OPERATIONAL FAILURE IS ATTRIBUTED TO
INADEQUATE BOILER FEEDWATER TREATMENT.

Table 9.2.1 – Recommended limits for boiler water (based on drum water analyses).
Pressure at Outlet of Total OH Silica Phosphate Sulfite Hardness Chlorides
Steam Generating Solids Alkalinity ppm ppm ppm ppm ppm
Unit, PSIG ppm ppm
0-150 2,000 200 50 50 30 0 250
151-450 1,500 100 35 50 30 0 200
451-750 1,000 60 25 25 25 0 150
751-900 750 55 10 25 20 0 50

9.3 Effects of deposits and harmful ions on turbine

Efficiencies in a steam turbine are sensitive to surface finish because of the high velocities and sharp
turning that are required by the design. While corrosion and stress corrosion problems are unusual in
steam plants, such problems can result from boiler carry-over due to inadequate deaeration and
boiler feedwater treatment.

The chloride ion which is present in most industrial water, can cause stress corrosion problems, but
most typically it is associated with the pitting of turbine blades and nozzles, especially in the presence
of oxygen.

35
9.4 Detection of deposits

Indication of the accumulation of deposits in the steam path could include:

• Increased stage pressure.

• Reduced power output.
• Increased active thrust with increased oil or bearing temperatures in the thrust bearing.
• Excessive vibration

If deposits are observed in the turbine during inspection, samples should be taken and submitted for
chemical analysis by a laboratory to determine their make-up and what action is required to remove
them from the system.

9.5 Detection of corrosion

Indications of corrosion may be difficult to determine. A steam turbine’s efficient performance dictates
that its steam path possess tight corners and crevices, these areas can be susceptible to pitting due
to the collection of condensate that possesses harmful ions. The turbine’s blade and first stage
nozzles should be inspected during scheduled shutdown via borescope. If possible the upper half
casing should be removed, under supervision of a Dresser-Rand Service Representative for better
inspection.

Pitting of the blades and nozzles is evidence of a corrosive attack, making them susceptible to stress
corrosion cracking. Dresser-Rand’ Service Department should be consulted prior to restart of the
turbine. If residue or condensate is present in the turbine and corrosion is present, samples of the
residue or condensate should be submitted for chemical analysis to determine the presence of
excessive chlorides and other harmful ions.

36
 10

OFF-SEASON STORAGE
10.1 Introduction

Many of our turbines are used as “seasonal machines”, being out of service for as many as six to
eight months of the year. During the off-season, many turbines are subjected to moisture and
contaminants which will shorten the life expectancy of the machine. The turbine must be protected
from corrosion internally with a vapor type of corrosion inhibitor introduced in crystal form or clean dry
air/nitrogen purge.

The following suggested preventative maintenance procedures will greatly reduce the possibility of
damage to the turbine due to off-season storage. Frequent inspections, both internal and external,
for evidence of rust should be made. Cleaning and reapplication of preventatives may be necessary.

10.2 Turbine steam path

The following procedures are recommended to prevent off-season deterioration of the steam path:

• Gland cases should be opened, dried and inspected. If gland cases do not have removable
covers, low pressure air may be blown through drain lines to assist in drying the gland area.

Turbines having “sealing steam” must have a positive shut-off or disconnect to prevent steam
from entering the turbine inadvertently. Gland steam lines and drains should be capped to
prevent moisture from re-entering the turbine.

For extended storage, the carbon rings should be removed to prevent pitting of the shaft that may
occur due to any condensation.

• Warm, dry air may be circulated through the turbine to remove moisture from the steam path. Air
may be introduced through some other casing opening such as a handvalve boss.

The air can be exhausted through the exhaust flange, vacuum breaker, port or casing drains.

• Steam inlet and exhaust must have positive shut-off or disconnect to prevent steam entering the
turbine.

CAUTION: A PRESSURE RELIEF VALVE MUST BE INSTALLED BETWEEN THE EXHAUST

FLANGE AND EXHAUST LINE POSITIVE SHUT-OFF.

• Several types of rust preventatives are available and can be placed into the turbine casing to help
keep the turbine dry. If this type of corrosion inhibitor is used the main steam inlet and exhaust
connection must be sealed off with blank flanges (wood or metal) to prevent the loss of the vapor
inhibitor.

• Electric magnetic heaters can be applied to the casing to help keep the turbine dry.

• The turbine rotor should be rotated 450° once a week to eliminate any permanent bowing.
Bearings must receive lubrication before this is done.

• All valving needs to be exercised.

37
10.3 Lubrication System

The following procedures are recommended for preparing the lubrication system for off-season
storage:

• The complete lubrication system must be drained and cleaned. NEVER STORE A TURBINE
WITH OLD OIL IN IT. Contaminants in the oil may cause the turbine shaft to become etched
under the journal bearings.

• All low points in the lubrication system should be checked for moisture and cleaned as required.
Low points include bearing cases, power cylinders, drive gear cases, pilot valves, oil reservoir,
etc.

• Fresh oil should be circulated through the lubrication system prior to storage.

• Cooling water to oil coolers should be positively shut off or disconnected. Drain water from cooler
if lubrication system is an outdoor installation.

10.4 Other recommendations

If the turbine is to be idle for a period longer than eight months, Dresser-Rand should be consulted as
to the proper storage procedures. Any other questions or concerns regarding off-season storage
should be directed to the Dresser-Rand representative or the factory.

38